Thermopatch Deco-Print DP2000T Operator's Manual

Introduction to the Deco-Print, from Thermopatch ............................................................................... 7 Section 2 .................................................................................................................................................... 11 DP2000T SETUP ..................................................................................................................................... 11 Step 1 ................................................................................................................................................ 11 Step 2 ................................................................................................................................................ 13 Step 3 ................................................................................................................................................ 13 Step 4 ................................................................................................................................................ 14 Step 5 ................................................................................................................................................ 15 DP2000T Transfer Specifications ........................................................................................................... 18 DP2000T Transfer Setup ........................................................................................................................ 18 Ribbon Tape Setup Feed Adjustment ................................................................................................... 21 Adjusting the Printing Pressure and Platen Height printing Pressure .............................................. 22 Printing Platen Adjustment ............................................................................................................... 22 Setup for (2) or More Ribbons .......................................................................................................... 22 INSERTING THE PRINTING PLATE .......................................................................................................... 23 Choosing The Platen ......................................................................................................................... 24 Testing The Transfer Roll Feed Set-Up .............................................................................................. 24 Testing the Ribbon Feed Roll Set-Up ................................................................................................ 24 Correcting Take-Up Problems ........................................................................................................... 24 Section 3 .................................................................................................................................................... 25 CONTROL BOX ....................................................................................................................................... 25 Machine Setup ...................................................................................................................................... 27 Section 4: Troubleshooting ....................................................................................................................... 28 OPERATIONAL MESSAGES ..................................................................................................................... 31 Section 5: Parts Identification and Location ............................................................................................. 32 Section 6: Maintenance ............................................................................................................................ 51 Rubber Print Platen ............................................................................................................................... 51

General .................................................................................................................................................. 51 Teflon/Fiberglass Shield (Used for Heat Sealing) .................................................................................. 51 Shipping the DP2000T ........................................................................................................................... 51 Section 7: Customer Service ..................................................................................................................... 52 Thermopatch Customer Service ............................................................................................................ 52

Figure 2 — Display .................................................................................................................................... 12 Figure 3 — Electrical Plugs Connected ..................................................................................................... 12 Figure 4 — Heater Cover Assembly, Installation ...................................................................................... 13 Figure 5 — Air Filter/Regulator, Installation ............................................................................................. 13 Figure 6 — Electrical Enclosure Assembly, Outside view ......................................................................... 14 Figure 7 — Head Assembly, no Flanges .................................................................................................... 15 Figure 8 — Head Assembly, with Flanges ................................................................................................. 15 Figure 9 — Transfer Roll Threading .......................................................................................................... 16 Figure 10 — Ribbon Roll Threading .......................................................................................................... 17 Figure 11 — Sensor ................................................................................................................................... 19 Figure 12 — Sensor location ..................................................................................................................... 19 Figure 13 — Sensor Position ..................................................................................................................... 20 Figure 14 — DP2000T Machine Assembly ................................................................................................ 32 Figure 15 — Platen Assembly ................................................................................................................... 33 Figure 16 — Press Arm Assembly ............................................................................................................. 34 Figure 17 — Heater Assembly .................................................................................................................. 35 Figure 18 — Support & Switch Assembly ................................................................................................. 36 Figure 19 — Head Assembly ..................................................................................................................... 37 Figure 20 — Front Plate Assembly ............................................................................................................ 38 Figure 21 — Rear Plate Assembly ............................................................................................................. 39 Figure 22 — Laser Assembly ..................................................................................................................... 40 Figure 23 — Dancer Roller Assembly ........................................................................................................ 41 Figure 24 — Touch Guard Assembly ......................................................................................................... 42 Figure 25 — Heater Cover Assembly ........................................................................................................ 43 Figure 26 — Pneumatic Diagram .............................................................................................................. 44 Figure 27 — Valve and Regulator Assembly ............................................................................................. 45 Figure 28 — Electronics Module ............................................................................................................... 46 Figure 29 — Main Electronics Module...................................................................................................... 47

Figure 31 — DC Harness ........................................................................................................................... 49 Figure 32 — Head Cover Assembly ........................................................................................................... 50

in material and workmanship under normal use and service. Any part which proves to be defective in material or workmanship within one year of the date of original purchase for use, will be repaired or replaced, at Seller’s option, free of service or labor charges, with a new or functionally operative part. Seller’s liability under the Warranty shall be limited to repairing or replacing at its own factory or through an authorized service distributor or dealer, material which is determined by Seller to have been defective in manufacture and upon which a claim has been made by the original purchaser or user to Seller (or an authorized distributor or dealer) within the warranty period. Claims under this Warranty will be honored only upon written approval by an authorized officer of Seller. Approved return of parts or products will be on a prepaid transportation charges basis only. Claims under this Warranty will be honored only upon Seller’s determination that the claim is covered by this Warranty, and Seller shall incur no obligation under this Warranty prior to such determination. This Warranty does not apply: (1) To any machinery or equipment which has been altered or repaired, except by Seller or its authorized representatives, or (2) to any machinery or equipment which has been subject to misuse, negligence, or accident, including, without limitation, use and operation of such machinery or equipment while parts are loose, broken, out of order, or damaged by the elements. Parts replaced under this Warranty are warranted only through the remainder of the original Warranty. Any and all claims for warranty service must include such information as Seller designates, and shall include specifically the serial number of each unit (if appropriate). The foregoing shall constitute the sole and exclusive remedy of any using purchaser and the sole and exclusive liability of Seller in connection with this product. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, INCLUDING BUT NOT LIMITED TO, ANY WARRANTY OF MERCHANTABILITY OR FITNESS AND ALL OTHER OBLIGATIONS OR LIABILITIES OF SELLER, INCLUDING ANY TORT LIABILITY, FOR NEGLIGENT DESIGN OR MANUFACTURE OF THIS PRODUCT, OR OTHERWISE. It is expressly agreed that Buyer shall not be entitled to recover any incidental or consequential damages, as those terms are defined in the Uniform Commercial Code, and that Buyer shall have no right of rejection or of revocation of acceptance of any part or of revocation of acceptance of any part or all of the goods covered hereby.

The DECO-PRINT Model DP2000T machine is shipped with the printing platen assembly (hard rubber) installed onto the machine. The printing plate is not included and must be ordered separately. The machine cannot be used for direct printing without a printing plate installed into the machine. New features on this machine include: • A transfer sensor used to precisely align each transfer on the sealing platen as the transfer moves through the machine. • An adjustable laser target dot to assist the operator in positioning the garment for print / transfer. The DECO-PRINT Model DP2000T machine prints the customer’s logo or text directly onto the garment using the hard rubber platen, “C” tape, and a printing plate (not included). The printing plate is ordered separately in one of three configurations. 1. With the customer’s logo, 2. With a plate with tracks, or 3. With a combination of a logo and tracks for individual lettering. When using individual lettering, the type font kit, (not included), will need to be ordered separately. With the sealing kit installed, the Deco-Print Model DP2000T machine can be used for heat sealing individual labels, mending patches and for applying hot paper transfers. PLEASE NOTE: The time, temperature, and pressure settings needed to seal these products with the DP2000T may differ from the settings needed by other Thermopatch heat seal equipment. Contact a Thermopatch representative with any questions. The DECO-PRINT model DP2000T prints a permanent mark directly onto most natural or synthetic fabrics by means of a printing plate, briefly striking the inked ribbon against the material to be marked. The machine is an air operated machine that uses a foot pedal, (included), to initiate the printing cycle. The transfer roll or “C” tape roll advances by means of a motor drive. The transfer sensor is used to accurately locate the transfer in the correct position for each application. The heater is made from cast aluminum for durability. The electronic temperature control maintains the temperature within 5 degrees of the temperature setting for accurate printing / sealing conditions. The printing plate and sealing plate slide into guides mounted onto the sides of the heater. The plate can be easily changed by pulling the plate out and inserting another plate, using the plate holder (included).

• 46780 — (3) Separator discs. Used between different colored ribbon rolls (C-TAPE) on supply side. See page 21. • 46007 — Plate holder. • 47312 — the Standard (SAE) Tool Kit (after January 2015) • 47309 — 1.5 M of 6 mm tubing (after May 2015) • 47310 — 6 mm OD Connection (after May 2015) PRINTING OPTIONS: • 45957 — Special adapter plate to mount narrow plates previously used in the Model PAP304 machine. • PM-1330 — TYPE FONT KIT, 94 pieces, ¼” high to fit standard print plates listed below. • PP0500-01 — Print plate with (1) track. • PP0500-02 — Print plate with (2) tracks. • PP0500-03 — Print plate with (3) tracks. • PP0500-04 — Print plate with (4) tracks. • PP0600-01 — Print plate with (1) extended track, up to 14 characters. • PP0600-02 — Print plate with (2) extended track, up to 14 characters. • PP0600-03 — Print plate with (3) extended track, up to 14 characters. CUSTOM PRINT PLATES Depending on a customer’s requirements, the printing plate may be an engraved plate, changeable type slugs, or a combination. This will allow you to: • Print property marks, logos, and other information on sheets and the inside layers of pants, jackets, and other garments. • Print company logos directly on suit bags, hospital linen, table linen, or shop wear. • Print any of the above with different colors - up to four, 1” wide ribbons or any combination up to 4” total width. Print plates can be fabricated to fit individual requirements using customer supplied artwork. Design can include tracks for individual type fonts or full phrase slugs. Maximum printing area is 4 ¾” x 3 ¾”. To print with (2) or more different colored ribbons, a relief or space between adjacent fonts or engravings should be 7/32”. The “C” tape ink ribbons are available in 13 standard colors, in 1”, 2”, 3”, and 4” widths. Custom colors are available. Contact customer service for information and pricing for custom colors.

The Safety Guard is activated in two ways: 1. The metal bar senses the touch of your hand. 2. There are switches that sense any obstruction. Once the safety guard is activated, the downward movement of the print will be interrupted and the “CLEAR” button must be pressed before the next print cycle. If an obstruction is met before this point, the power print cycle will not occur. There is an Emergency Stop switch, on the front of the machine that will immediately interrupt the machine at any point in the power printing cycle, and return to the normal positions. The switch must be reset before resuming operation. The electrical system is isolated and fully grounded. The electrical power cord must always be plugged into a properly grounded outlet. THE USE OF POWER STRIPS AND EXTENTION CORDS IS NOT RECOMMENDED CAUTION: PRESSURE READING ON AIR GAUGE MUST NOT EXCEED 100 PSI (7.0 BAR) CAUTION: THE PRINTING HEAD AND PLATE MAY REACH TEMPERATURES AS HIGH AS 550°F (288°C) DURING NORMAL OPERATION. ALWAYS KEEP HANDS CLEAR OF THE PRINTING HEAD WHEN OPERATING MACHINE. IF POWER IS ON, DO NOT LEAVE MACHINE UNATTENDED. IF A LOSS OF AIR PRESSURE OCCURS, AND IF A GARMENT IS RESTING ON THE PLATEN, THE HEAD CAN LOWER AND COULD CAUSE A FIRE. A CHECK VALVE IS BUILT INTO THE MACHINE TO PREVENT THIS, BUT WITH A LOSS OF AIR PRESSURE, THE HEAD WILL COME DOWN AT SOME POINT. WARNING: BEFORE OPERATING THE MACHINE, MAKE SURE ALL COVERS ARE IN PLACE, AND KEEP LOOSE JEWELRY AND CLOTHING CLEAR OF THE MACHINE DURING OPERATION. BEFORE SERVICING THE MACHINE, UNPLUG THE ELECTRICAL CORD, DISCONNECT THE AIR SUPPLY, AND LET THE PRINTING HEAD COOL DOWN TO ROOM TEMPERATURE CLEAN MACHINE PARTS WITH NON-FLAMMABLE CLEANING FLUIDS ONLY.

Or 2.5 Amps @ 220 VAC, 50/60 HZ Operating Air Pressure: 25 PSI (1.8 BAR) Minimum to 70 PSI (4.8 BAR) Maximum 1.3 CFM (0.6 Liters/sec) Dwell Time Setting: 0.1 Seconds to 99.9 Seconds Heat Range: 200°-500°F (93° - 260°C) Maximum Print Area: 4-3/4” wide x 3-3/4” deep Transfer Advance (Roll) Sensor controlled stop is adjustable from 7 ½” to 13 ½”from the centerline of the platen Ribbon Advance: 0.1” to 6.0” (2.5mm to 152mm) Ink Ribbon Width: 4, 3, 2, and 1 inch (102, 76, 51, and 25 mm) Multiple colors and widths any combinations up to 4” total width Opening Height: (Between Printing Plate and Platen) 5.0” (127 mm) Clearance: (From Back of Platen to Machine) 1-3/4” (44 mm) Weight: 115 lbs. 52 kg. FACTORY SETTINGS Temperature: 500°F (260°C) Transfer time: 2.0 seconds Label seal time: 12.0 seconds Printing time: 0.5 seconds Air Pressure: 50 PSI (3.5 BAR) Transfer (Roll) Advance: 5.0in (126-128mm) Ribbon Advance: 5.0 in (126-128 mm)

Loosen the two screws on the top of the case in the back and install the control box bracket, Item 4. Figure 1 — Control Box Bracket

Figure 2 — Display Plug the other end of the display cable, Item C, into the connector on the side of the machine. Figure 3 — Electrical Plugs Connected

Turn the “Emergency Stop” switch, Item A, in the direction of the arrow to make sure it is out. Figure 4 — Heater Cover Assembly, Installation Step 3 Refer to Figure 5 Attach the air filter/regulator, with fittings to the bulkhead fitting, Item A, on the back of the machine. Orient as shown with the gauge facing forward. Connect the air supply to the male hose adaptor, Item C. Figure 5 — Air Filter/Regulator, Installation

Connect the foot pedal plug into the FOOTSWITCH Plug, Item A. Connect the power line cord to power entry module, Item B, and to the power outlet. Turn on the machine by pressing the on/off switch, Item D. Item C depicts the display cable plugged in, previously discussed in connection on page 14 Figure 6 — Electrical Enclosure Assembly, Outside view

Place flange assemblies, Item A, on supply and take-up shafts, Item B. Figure 7 — Head Assembly, no Flanges Figure 8 — Head Assembly, with Flanges

DP2000T Transfer Setup 1. Select the transfer for use and measure the distance from the leading edge of one image to the leading edge of the next transfer as shown. A special platen is required if this measurement is less than 2-1/2 inches ( 64 mm ) 2. Install the transfers onto the machine. 3. Use the JOG button to feed the transfer image until the image is in the center of the sealing platen. 4. Press the MENU button. 5. Press the ENTER button until the display reads “ SET FEED LENGTH: “. 6. Subtract 2 tenths of an inch, (5 mm) from the transfer measurement in step 1 and use the UP or DOWN ARROW button to enter this number into the machine. Example – The transfer measures 3 inches, (76 mm) from leading edge to leading edge. Subtract 2 tenths of an inch, (5 mm) from 3 inches. The number entered into the machine should be 2.8 inches, (71 mm).

Use the UP or DOWN ARROW button to select YES. 8. Press the MENU button to exit the menu. 9. Loosen the clamp screw, move the transfer sensor onto the space between the transfer images and tighten the clamp screw. 10. Press the TRANSLUCENT button and hold it until the lights on the sensor stop blinking. NOTE: If green and red output lights are on and an * is displayed on the control box, push both (normal) and (translucent) buttons simultaneously. This procedure inverts the output to the correct status, green light on. Figure 11 — Sensor Figure 12 — Sensor location

image closest to the sealing iron. When the edge of the image is detected by the transfer sensor, an asterisk ( * ) will appear on the display next to the feed length. When you see the asterisk ( * ), on the display, tighten the clamp screw. Test the machine. The transfer image should be centered on the sealing platen. If the image is moving after each cycle, re-adjust the position of the transfer sensor. If the image is not centered, repeat the setup procedure. Figure 13 — Sensor Position

The first step is to adjust the feed. This feed value advances the tape after printing to the amount of the entered value, to set up for the next print. Using the control box, the user adjusts and controls the distance that the machine feeds. Caution: tape tension may cause less feed length than what the display indicates. (See page 24) for adjusting tape feed length. (See page 22, step 3) for adjusting tape tension. The distance between the left and right edges of the plate image determines the value for the amount of feed. Measure this distance and add .2 to .4 inches (5.1 mm to 10.2 mm) to it; this will give you your feed length. The feed length on the controller box needs to be changed to the measurement taken. We will use 5.2 inches (132 mm) as an example of a measurement.

Printing pressure is preset at the factory to 50 PSI. The printing pressure range is from 25 PSI (1.8 BAR) minimum to 70 PSI (4.8 BAR) maximum. NEVER EXCEED 70 PSI. In general, the larger the printing area, the higher the pressure required. The air regulator is located outside, at the rear of the machine. At the top of the regulator is a black knob. Pull upward to change the current setting. Turn the knob clockwise to increase the air pressure or counterclockwise to decrease the air pressure. After pressing down on the foot pedal and then releasing, check the air gauge reading. Readjust if necessary, then activate the foot pedal and release again for a new gauge reading. To lock in a setting, push the black knob down into its original position. Printing Platen Adjustment Occasionally, it may be necessary to increase the pressure on one corner or side of the printing platen in order to make it print better in that area. This might be true where an engraved design has a denser area in one corner. To adjust, locate the appropriate thumb screws below the rubber platen. Looking from the top, turn the screw counterclockwise to increase the pressure. NOTE: The platen is level when all screws are turned clockwise and the platen is put in its lowest position. Setup for (2) or More Ribbons 1. Multiple ribbons of different colors are threaded the same as a single ribbon shown in Figure 10 — Ribbon Roll Threading. a. The rolls must be separated by a thin disc, to prevent interaction, when they are different outside diameters. Three discs are provided in the Optional Printing Kit, and are to be used on the unwind, or supply shaft. 2. Place one roll on shaft followed by a disc and push to rear. Repeat this procedure for each roll added. No disc is required after the last roll added. Replace the supply flange and clamp collar. If a single ribbon is used, push the three thin separator discs to the rear, against the supply flange or remove from machine for storage. 3. Usually the outer clamp collar can be adjusted to minimize endplay of the roll, because of the drag from the roll insert on the shaft. If the roll turns freely on the shaft, push the clamp collar in to create drag on the roll. Too much drag may cause the ribbon to break or the motor to stall. Do not stall motor. 4. Thread the tape through the machine: Refer to Figure 10 for a visual aid. • Unroll approximately two feet of tape off the roll. • Feed the tape under the sensor roller, under the heating iron, up and around the feed roller, down under the dancer roll, and up to the take-up shaft. • Attach to take-up shaft as shown in Figure 10. • Press the JOG button until the tape is taut through the machine.

The above drawing shows a DP2000T Printing Plate (Item 1) (CUSTOM PART) and a Printing Plate Holder (Item2) P/N (46007). The Printing Plate Holder is provided for installation and removal of the Printing Plate. • With the artwork facing down on the Printing Plate, apply a downward force just enough to slide the Printing Plate Holder forward. This locks the Printing Plate into place. • Insert the plate into the plate mounting brackets on either side of the iron. • Slide the plate in fully. • Apply the same downward force and slide the Printing Plate Holder away from the machine. To remove the Printing Plate from the machine, just reverse the process. The Printing Plate is extremely HOT so caution must be taken when removing and placing it on a heat protective surface. Avoid any side to side motion of the Plate Holder while inserting or withdrawing Print Plates. This motion tends to bend side guides and loosen heater mounting screws. Note: If you bump the touch guard, press the CLEAR button on the controller box to reset.

Be sure to use the proper platen. Use the hard rubber platens for printing, and the soft rubber platen for heat sealing and dry ink transfers. There should be a distance of at least 1/8” to 1/4” between the printed image and the outer edge of the platen. Testing The Transfer Roll Feed Set-Up Run the machine through a few cycles holding a scrap cloth in place over the platen. Check to see if the machine is properly feeding the transfer tape, enough to position the next transfer in the correct position. The transfer image target position is controlled by the location of the sensor when it stops the following transfer. To change this position, move sensor roll arm and retighten clamp screw. The machine is ready for operation. Testing the Ribbon Feed Roll Set-Up Run the machine through a few cycles holding a scrap cloth in place over the platen. Check to see if the machine is properly feeding the tape, enough to clear for the next print. There should be a gap of 1/4” or more between the printed images on the used tape. If there is less than 1/4”, increase the feed value slightly. If there is more than 1/4”, decrease the value slightly to reduce waste. Correcting Take-Up Problems Check that the used ribbon or transfer tape on the take-up shaft is not trying to fold over on the flange. If it is, the take-up flanges can be moved to the front or back of the machine to compensate. If this tracking problem continues, check for the following causes: 1. Not enough tape tension. Push in on the outer supply flange and tighten the thumb screw to produce more drag. A slack tape will tend to creep down the slope of the feed roll, since it is feeding in the up position. 2. The dancer or sensor roll being out of alignment. These rolls must be parallel, both horizontal and vertical with feed roll. The brackets these rolls are mounted to could become bent during shipment or by being bumped. Usually they can be bent and gauged by eye to the correct position. Make sure the used end of the ribbon is attached as shown in Figure 10. If the ink side of the ribbon is touching the take-up shaft or it’s slot, or if tape tension is excessive the slot will close in and the used roll will be difficult to remove. The machine is ready for operation.

The display on the control box in normal running mode shows: Feed Length * Print Time * (means sensor is sensing stop position on transfer) Temperature Daily Counter Press the UP or DOWN button once to change the Daily Counter (DC) to Continuous Counter (CC). NOTE: The software version number will appear when machine is turned on. To zero the Daily Counter (DC), press the UP and DOWN buttons simultaneously while the Daily Counter (DC) is displayed. The Mode button switches the display to menu mode with 2 selections. MACHINE SETUP JOB SETUP

1. Display language (English, Nederlands, Italanio, Deutsch, Francais, Espanol) 2. Temperature scale (Fahenheit, Celcius) 3. Feed length (Inches, Millimeters) 4. Counter mode (Daily, Continuous) The JOB SETUP menu is used to set: 1. Temperature 2. Feed length 3. Print or Seal time 4. Seal only option 5. Pattern marker option Press the ENTER button to cycle through the menu options when in menu mode. The UP and DOWN arrow buttons increase or decrease the settings. The JOG button advances the tape. Note: Once the Touch Guard is activated, you must press CLEAR before the machine can print.

MACHINE SETUP. 1. Press ENTER and select language. Press UP or DOWN button to select ENGLISH. 2. Press ENTER and choose the temperature scale. Press UP or DOWN button to select FAHRENHEIT. 3. Press ENTER and select feed length unit. Press UP or DOWN button to select INCH. 4. Press and choose the counter, DC or CC. Press UP or DOWN button to select DC (daily counter). Press Enter to save the last setting. JOB SETUP: To run Transfer Roll Press MODE and select JOB SETUP with UP or DOWN button. Press ENTER and set temperature at 500 degrees F, or to suit, with UP or DOWN button. Press ENTER and set Feed Length at 4 inches by pressing UP or DOWN button Press ENTER and set Print Time at 2 seconds by pressing UP or DOWN button. Press ENTER and set Seal Only to NO, with the UP or DOWN button. Press ENTER and set Pattern Marker to YES with the UP or DOWN button. Press ENTER to save the last setting. If the Job is using Ribbon (C-Tape), set Pattern Marker to NO. Leave Seal Only set to NO. Change temperature, feed length, and time to suit. If the JOB is to seal individual labels, patches, or transfers, set Pattern Marker to NO. Set Seal Only to YES, this will disable the roll feed. Set temperature, time, and pressure to suit. Press ENTER Button after each selection to save the settings. The machine will automatically exit the menu mode if none of the buttons are pressed within 5 seconds.

Before referring to the information below, check for proper set-up and operation as outlined in “DP2000T Setup”. Solutions are listed with the most probable ones listed first. Some procedures may require completion by a person with some mechanical and electrical skill. Call Customer Service for assistance or to order replacement parts. Problem Possible Cause Solution Display is blank Machine is unplugged or outlet has no power Emergency stop activated Electrical power switch or light not “ON” or is defective Loose or broken wires or connectors Check Check Check/Replace Check/Repair No heat Machine is unplugged or outlet has no power Electrical power switch is not “ON” or is defective Temperature reading is incorrect Print Head heat is defective Heat sensor is defective Defective temperature control Loose or broken wires or connectors High limit thermostat is defective Check Check/Replace Replace Replace Replace Replace Check/Repair Replace High or low heat Heat sensor is defective Defective temperature controller Temperature reading is incorrect Loose or bad connectors Short between sensor wires (high heat only) Replace Replace Adjust Check/Repair Check/Repair Print pressure drops or fluctuates (on air (gauge) or hisses Leak in air supply hose Dust is lodged in the air lines, regulator, or solenoid air Valves Repair/Replace Disassemble and clean

not descend Touch guard activated Temperature not ready Solenoid air valve not shifting Air supply not connected Foot switch is unplugged or bad Leak or restriction in air line or connections Press Clear Wait Replace Check Check/Replace Check/Repair Print head too slow or fast Flow control(s) adjustment is incorrect Mechanical binding See pg.44 item 14 Check & Correct Timed power print cycle does not activate Garment or cloth is too thick Leak in hose or connections Defective microswitch Mechanical binding Check Repair/Replace Replace Check & Correct Print Head does not rise to the open position Air solenoid valve not shifting Leak or restriction in air line connections Mechanical binding Check/Replace Check/Repair Check & Correct Overall print is too light Air pressure is too low Temperature is too low Time setting is too low See pg 22 See pg 27 See pg 27 Parts of design are not printed In ribbon feed not working properly Rubber print platen is dirty or worn In ribbon to properly guided left to right Overlap of printed impressions in used ink ribbon Ink ribbon not wide enough One corner of rubber platen needs adjustment Check threading per pg 17 Clean or replace Check ink ribbon threading Adjust longer, see pg 24 Use wider ribbon See pg 22 Center of “O”, “A”, etc is filled with ink; imprint is unclear Temperature is too low Time setting is too low Engraved plate is dirty Pressure incorrect See pg 27 See pg 27 Clean Clean & Correct

are used, print is unclear Type slugs are dirty Deformed type slugs caused by high heat Pressure incorrect Clean Adjust heat per pg 27; replace slugs Check & Correct Ink marks on back side of garment Ink build-up on rubber platen Clean Platen. See pg 51 Emergency stop push button will not operate Push button is defective Replace, see pg 43

The temperature wait message shown at the main display will be replaced by the continuous count or the daily count when the temperature is within 15 degrees Fahrenheit or 7 degrees Celsius of the set point temperature. The operator can change options during the warm-up period. Temperature Controller Messages The temperature controller will be interrogated and if a fault is detected one of the following messages will appear: Line 1 Meaning/Response Heater Failure Logic board Temperature control board is either bad or unplugged Heater Failure Heat Sensor Temperature sensor is either bad or disconnected Heater Failure Slow heat rise Heater is bad or disconnected; or temperature sensor is bad, disconnected, or shorted Heater Failure High temperature Relay is bad or shorted; temperature sensor is bad or shorted; or bad connections Heater failure Unknown Contact Thermopatch Seal Switch ERR Display when touch guard is activated. This indicates the seal down switch was not activated During a seal cycle if the top platen did not come down Check seal down switch and wiring TOUCH GUARD FAULT This indicates the guard was hit. Press the CLEAR Button.

Figure 14 — DP2000T Machine Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 1 46876 CASE WELDMENT 1 2 PLATEN ASSEMBLY SEE PAGE 33 1 3 46882 COVER, TOP REAR 1 4 46788 BRACKET, CONTROL BOX 1 5 21021-06-C NO. 8 SPLIT LOCKWASHER 8 6 21028-36 HEX STANDOFF #8-32 4 7 45678 COVER, CASE FRONT 1 8 21058-05-F PHS 8-32 X 3/8 LG 4 9 21021-07-C NO. 10 Spring 11 10 21061-02-E BUTTON HD 10-32 X 3/8 LG 11 11 20220-37 SHIELDED SERIAL CABLE 1 12 21028-38 RUBBER BUMPER 4 13 21060-04-H BHS 10-32 X 5/16 LG 4 14 45426 LABEL, HIGH VOLTAGE 2 15 43025 FOOT SWITCH W/GUARD 1 16 PNEUMATICS SEE PAGE 44 2 17 HEAD ASSY SEE PAGE 37 1 18 ELECTRONICS MODULE SEE PAGE 46 1 19 44771 LABEL – MADE IN USA 1 20 20080-70 CORD – LINE 110V IEC CONN 1 21 46879 PLATE, R.H. SIDE 1 22 47149 LCD CONTROL MODULE 1

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 45587 PLATEN BLOCK 1 2 45619 RETAINER, PLATEN HOLDER 1 3 45582 PLATEN HOLDER GUIDE WELDMENT 2 4 45621 PLATEN HOLDER 1 5 45642 SCREW ASSY 4 6 21029-32 THUMB SCREW 1/4-20 X 3/4 LG X 3/4 4 7 21062-03-D FLAT SOC HD SCR 8-32 X 1/2 4 8 24075-26 SPRING - COMPRESSION 4 9 46833 COVER, PLATEN BASE 1 10 45637 HARD RUBBER PLATEN 2 11 21069-03-E PHS 6-32 X 1/4 LG SS 4 12 45620 STOP, PLATEN HOLDER 1 13 21021-05-C # 6 SPLIT LOCKWASHER 8 14 21006-06-C SHLD SCR 3/8 X 1 1/4 LG 1 15 21061-01-B BUTTON HD SCR 6-32 X ¼” 4 Note 1: If the machine is set up for printing, use print platen (45637.) If the machine is set up for transfers, use sealing pad assembly (46009)

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 45591 ARM SUPPORT ASSY 1 2 22010-57 PIVOT MOUNT BRKTS (BIMBA) 1 3 22010-56 AIR CYLINDER, 2 1/2 BORE 3 1/2 1 4 45578 UPPER LINK ASSY 1 5 46055 LOWER LINK ASSY 1 6 45589 CLEVIS, SEALING CYLINDER 1 7 21051-20-C NUT, HEX JAM 1/2-20 1 8 45593 SHAFT, PRESS ARM 1 9 24016-22 SET SCREW COLLAR 3/8 BORE 2 10 21021-09-C LOCKWASHER - SPLIT 1/4 10 11 21011-04-H SET SCR 8 X 32 X 3/16 2 12 21022-12 THRUST WASHER 3/8 2 13 45573 SHAFT, CENTER LINK PIVOT 1 14 21011-05-L SET SCW - CUP 1/4-20 X 1/4 LG 4 15 45583 SHAFT, LOWER LINK PIVOT 1 16 22015-34 ELBOW - 1/4 MPT X 3/8 TUBE 2 17 21029-48 BUT HD 8 X 32 X 3/8 2 18 21021-06-C NO. 8 SPLIT LOCKWASHER 2 19 46937 COVER, FRONT 1 20 21063-08-K SHCS 1/4-20 X 1.0 LG 8 21 21051-11-A HEX NUT 1/4 - 20 4 22 HEATER ASSY SEE PAGE 35 1 23 SUPPORT/SWITCH ASSY SEE PAGE 36 1 24 46947 PRESS ARM MACHINING 1 25 21023-23 NO. 8 FLAT LOCKWASHER 2

ITEM NO. PART NUMBER DESCRIPTION QTY. 1* 45585 SEALING IRON MACHINING 110V 1 2 45579 ISOLATOR BLOCK 1 3 45849 GUIDE WELDMENT, 2 4 45643 STOP, PRINTING PLATE 1 5 21021-10-C LOCKWASHER #5/16 SPLIT 2 6 21050-192 SHCS 5/16-18 X 2.0 LG S.S. 2 7 21021-06-C NO. 8 SPLIT LOCKWASHER 10 8 21069-05-E PHS 6-32 X 3/8 LG SS 2 9 21069-03-E PHS 6-32 X 1/4 LG SS 6 10 21021-06-B LOCKWASHER - EXT NO. 8 1 11 21069-03-F PHS 8-32 X 1/4 LG SS 1 12 45451 ADAPTER, HIGH LIMIT 1 13 20018-24 THERMOSTAT- HI LIMIT 1 14 21069-02-E PHS 6-32 X 3/16 LG SS 2 15 46942 PLATE, PRINT GUIDE SUPPORT 2 16 46904 TEMPERATURE SENSOR ASSY 1 17 21023-03 5/16 FLAT WASHER 2 Notes: 1. For a 220V machine, use sealing iron #45639 2. Apply anti-seize compound to threads when mounting. Torque to 60 in-lbs and re-torque after initial heating. 3. If machine is set up for printing, use custom print plate or multi-track print plate. See page 23

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 45576 STUD, PIVOT 1 2 21062-05-G FHSCS 1/4 - 20 X 3/4 LG 1 3 21021-09-C LOCKWASHER - SPLIT 1/4 4 4 21061-03-F BUT HD SCR 1/4 X 20 X 1/2 3 5 45613 BRACKET, SEAL SWITCH 1 6 45712 NUT PLATE, SEAL SWITCH 1 7 20055-73 SWITCH - MICRO 1 8 21033-03-C SPRING PIN, 1/8 X 3/8 LG 1 9 21029-48 BUT HD 8 X 32 X 3/8 2 10 21021-06-C NO. 8 SPLIT LOCKWASHER 2 11 21023-22 WASHER - FLAT NO. 6 2 12 21057-08-C RHS 4-40 X 5/8 LG 2 13 21021-03-A NO. 4 LOCKWASHER, INTERNAL 2 14 46940 ROD, SUPPORT 1 15 21011-04-H SET SCR 8 X 32 X 3/16 1 16 46946 SUPPORT, WELD & MACHING R.H. 1

ITEM NO. PART NUMBER DESCRIPTION QTY 1 46893 FLANGE ASSY 4 2 46916 DRIVE ROLL ASSY 1 3 TOUCH GUARD ASSY SEE PAGE 42 1 4 COVER ASSY, HEATER SEE PAGE 43 1 5 REAR PLATE ASSY SEE PAGE 39 1 6 21011-04-K SET SCREW 10-32 X 3/16 LG 4 7 COVER ASSY, HEAD SEE PAGE 5-13 1 8 21063-05-K SHCS 1/4 - 20 X 5/8 LG 4 9 21021-09-C LOCKWASHER - SPLIT 1/4 4 10 FRONT PLATE ASSEM SEE PAGE 38 1 11 21065-05-D THUMB SCREW 10-32 X 1" W/ NYLON 4 12 46895 SHAFT, TAKE UP 1 13 DANCER ROLL ASSY SEE PAGE 41 1 14 21021-07-C NO. 10 SPLIT LOCKWASHER 11 15 21060-05-H BINDER HD 10-32 X 3/8 LG 11

ITEM NO. PART NUMBER DESCRIPTION QTY 1 46899 BRACKET, SENSOR 1 2 46900 SHAFT, SENSOR ROLL 2 3 46901 PLATE, SENSOR BRACKET SPACER 1 4 46902 SPACER, CLAMP SCREW 1 5 21023-02 WASHER, FLAT 1/4 1 6 21006-01-B SHOULDER SCREW 5/16 X 3/8 LG 1 7 21050-232 BELLEVILLE DISC SPRING .317 X .625 X .042 2 8 D-9702 E-RING 1/4 4 9 20055-73 SWITCH - MICRO 1 10 21057-08-C RD HD 4 X 40 X 5/8 2 11 46885 PLATE, FRONT 1 12 46939 ROLLER, IDLER 2 13 46941 THUMB SCREW ASSY 1/4-20 X 5"LG 1 14 46943 SPACER, MACHINE HEAD PLATES 1 15 46921 SPACER, HEAD PLATE 2 16 21021-07-C NO. 10 SPLIT LOCKWASHER 16 17 21021-09-C LOCKWASHER - SPLIT 1/4 1 18 46903 BRACKET, SENSOR ADJ. 1 19 46944 SENSOR ASSEMBLY 1 20 21023-02 WASHER, FLAT 1/4 2 21 21051-11-A HEX NUT 1/4 - 20 5 22 21051-03-A NO.4-40UNC HEX NUT, ZINC PLATED 2 23 21060-05-H BINDER HD 10-32 X 3/8 LG 16 24 21058-13-F PHS - 8-32 X 1 1/4 LG 2 25 21021-06-C NO. 8 SPLIT LOCKWASHER 4 26 21051-07-A HEX NUT - NO. 8-32 4 27 D-1453-1 CLAMP - 3/16 CABLE 2 28 21058-07-F PHS 8-32 X 1/2 LG 2 29 21023-23 WASHER - FLAT NO. 8 2

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 46886 PLATE, REAR 1 2 46778 SHAFT, UNWIND 1 3 D-9705 E-RING 3 / 8 3 4 46936 BRACKET, LASER SPRING 1 5 46915 SHAFT, DRIVE ROLL 1 6 46919 PIN, DRIVE ROLL SPRING 1 7 DF-7180 SPRING - EXT LE-029C-4 2 8 D-9701 E-RING 3 / 1 6 2 9 D-9702 E-RING 1/4 2 10 24080-36 SPRING - EXT LE-031C-1 2 11 21063-03-J SHCS - 10-32 X 3/8 LONG 6 12 LASER ASSY SEE PAGE 40 1 13 46881 SHAFT, TAKE-UP DRIVE 1 14 21021-09-C LOCKWASHER - SPLIT 1/4 1 15 46892 MOTOR ASSY, CAPSTAN 1 16 46891 MOTOR ASSY, TAKE-UP 1 17 24035-26 GEAR, 60T 32DP 1/4 BORE 2 18 24035-27 GEAR, 24T 3/8 BORE MODIFIED 2 19 21021-07-C LOCKWASHER - SPLIT NO. 10 6 20 21061-03-F BUT HD SCR 1/4 X 20 X 1/2 1

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 46922 YOKE, LASER 1 2 46934 PIVOT BLOCK, LASER 1 3 46933 PIN, LASER BLOCK 1 4 46935 BRACKET, LASER BLOCK 1 5 D-9701 E-RING 3/16 2 6 21058-03-F PHS 8 - 32 X 1/4 LG 2 7 21021-06-C NO. 8 SPLIT LOCKWASHER 2 8 21011-04-H SET SCREW 8-32 X 3/16 LG 1 9 46896 LASER LIGHT ASSY 1

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 46912 BLOCK, LEAF SPRING 1 2 46914 LEAF SPRING 1 3 46913 HANDLE, SPRING 1 4 46909 SHAFT, PIVOT 1 5 46905 DANCER ROLL ARM 1 6 46910 ARM ASSY, SPRING 1 7 21011-04-K SET SCREW 10-32 X 3/16 LG 2 8 D-9702 E-RING 1/4 2 9 21021-07-C NO. 10 SPLIT LOCKWASHER 2 10 46939 ROLLER, IDLER 1 11 21060-05-H BINDER HD 10-32 X 3/8 LG 2

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 46053 SPRING BRKT, R.H. 1 2 46054 SPRING BRKT, L.H. 1 3 21022-12 THRUST WASHER 3/8 2 4 46056 PIN, SHOULDER 2 5 21050-111 COTTER PIN 1/16 X 1/2 LG 2 6 45612 SPRING RETAINER 2 7 24075-39 SPRING, COMPRESSION 2 8 21060-04-C BHS 4-40 X 5/16 LG 2 9 21021-03-C NO. 4 SPLIT LOCKWASHER 6 10 45606 TOUCH GUARD WELDMENT 1 11 45605 SPACER, TOUCH GUARD 2 12 45604 INSULATOR, TOUCH GUARD 2 13 21063-08-K SHCS 1/4-20 X 1.0 LG 2 14 21021-09-C 1/4 SPLIT LOCKWASHER 2 15 45657 PLATE, R.H. SWITCH MTG 1 16 45658 PLATE, L.H. SWITCH MTG 1 17 20056-23 SWITCH - MICRO 2 18 21021-06-C NO. 8 SPLIT LOCKWASHER 4 19 21058-03-E PHS 6 - 32 X 1/4 LG 4 20 21057-08-C RHS 4-40 X 5/8 LG 4 21 21021-07-C NO. 10 SPLIT LOCKWASHER 4 22 21063-03-J SHCS - 10-32 X 3/8 LONG 4 23 46948 BRACKET, R.H. GUARD SWITCH 1 24 46949 BRACKET, L.H. GUARD SWITCH 1

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 46884 COVER, HEATER 1 2 45597 TAPE GUIDE 2 3 46938 LABEL, DP2000T FRONT 1 4 20055-75 STOP SWITCH ACTUATOR 1 5 20056-28 CONTACT BLOCK, E-STOP 1 6 21021-06-C NO. 8 SPLIT LOCKWASHER 4 7 21069-03-F PHS 8-32 X 1/4 LG SS 4 8 46880 SCALE, 4" TAPE WIDTH 2 9 45426 LABEL, HIGH VOLTAGE 1

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 DH-6786 NIPPLE - HEX 1/4 NPT 3 2 DH-6761 ELBOW - 90 DEG 1/4 NPT 3 3 DH-6797 ADAPTER - MALE HOSE 1/4 MNPT 1 4 22030-38 FITTING - BULKHEAD 1/4 NPT 1 5 22046-09 AIR FLOW CONTROL RT ANGLE 1/4 NPT 2 6 22015-34 ELBOW - 1/4 MPT X 3/8 TUBE 3 7 22005-45 CONN - 1/4 MPT X 3/8 TUBE 5 8 22030-09 POLY-FLOW 3/8 O.D X 1/4 I.D. 65.5" 9 22045-89 VALVE - IN LINE CHECK 1/4 NPT 1 10 22010-56 AIR CYLINDER, 2 1/2 BORE 3 1/2 STROKE 1 11 22030-53 BRANCH WYE 1/4 MPT X 3/8 TUBE 1 12 22045-84 MUFFLER 1/4 MPT 1 13 20081-57 VARGLAS SLEEVING 7/16 24" 14 46898 AIR SOLENOID W/CONNECTOR 1 15 22045-91 AIR FILTER/REGULATOR & GAUGE 1 NOTE 1: FOR A 220V MACHINE, USE 22045-94 REGULATOR 0-10 BARS. NOTE 2: PUSH BUTTON TO REMOVE AIR PRESSURE, THIS WILL PERMIT HEAD TO BE LOWERED FOR SHIPMENT OR MAINTAINANCE.

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 22045-91 AIR REGULATOR/FILTER/GAUGE 0-150 PSI 1 2 DH-6786 NIPPLE - HEX 1/4 NPT 3 3 DH-6761 ELBOW - 90 DEG 1/4 NPT 2 4 DH-6797 ADAPTER - MALE HOSE 1/4 MNPT 1 5 22030-38 FITTING - BULKHEAD 1/4 1 6 22045-89 VALVE - IN LINE CHECK 1/4 NPT 1 7 22046-09 AIR FLOW CONTROL RT ANGLE 1/4 NPT 2 8 22015-34 ELBOW - 1/4 MPT X 3/8 TUBE 1 9 22005-45 CONN - 1/4 MPT X 3/8 TUBE 5 10 21058-15-I PAN HEAD SCREW 1/4-20 X 1 3/4 2 11 21021-09-C 1/4 SPLIT LOCKWASHER 2 12 21051-11-A HEX NUT 1/4 - 20 2 13 TUBE, 2.0 POLY-FLOW 3/8 O.D X 1/4 I.D. 1 14 46898 AIR SOLENOID ASSY W/CONNECTOR 1 NOTE 1: FOR A 220V MACHINE, USE 22045-94 REGULATOR 0-10 BARS. NOTE 2: SEE Figure 26 — Pneumatic FOR COMPLETE PNEUMATIC DIAGRAM.

ITEM NO. PART NUMBER DESCRIPTION QTY. 1 46883 COVER, HEAD 1 2 21029-60 THUMB SCREW, 1" DIA KN'D HD, 1/4x20x1-1/4 LG 2 3 D-7212 ACORN HEX NUT 1/4-20 2 4 45426 LABEL, HIGH VOLTAGE 1 5 46945 LABEL, LASER TARGET 1

Rubber Print Platen Clean often by wiping with a soft, clean rag. Replace the pad when it becomes worn. To replace pad, slide old pad assembly out of the lower platen, and install a new assembly. Compressed Air Supply Maintain a filtered air supply. Check air filter daily. Drain by pushing up on button at bottom of filter bowl. General Keep inside of machine free of foreign material, including lint. Teflon/Fiberglass Shield (Used for Heat Sealing) Clean often by wiping with a soft, clean rag. A non-flammable cleaner such as “EZ-Off”, part no. DH- 6873, may be used according to the manufacturer’s instructions. Never use a flammable solvent or abrasive cleaner on this surface. Shipping the DP2000T Reverse the setup procedure shown above. A check valve between the air supply and the air cylinder will prevent the head from lowering. To lower the head, remove the Cover, Top Rear, Item 3 on page 32. With a pen or other tool, push the button on the air solenoid to relieve pressure to the air cylinder. The air solenoid is located on the left side at the rear of the machine, slightly forward of the cover opening. See page 45. Ship the machine in a suitable shipping container, preferably the container in which you received the machine.

Thermopatch Customer Service Thermopatch Corporation’s U.S. and International network of Sales Representatives, as well as its internal Customer Service Department, offer their assistance in the development of effective heat-seal mending, marking, and identification programs. Thermopatch markets a complete line of heat-seal and marking machines, as well as a complete line of materials and supplies. • Label Print Machines – Manual, automatic, and computer controlled. • Marking Machines – High speed permanent imprinting of decorative or informative marks on most woven fabrics. • Heat-Seal Machines – Manual, semi-automatic, and completely automatic, with high inter- platen pressure to assure excellent adhesion of label tapes and mending materials. • Label Tapes – Specially woven 100% cotton and blends with adhesives to match specific processing requirements. • The Deco-Print line of products has been specifically designed to offer alternative solutions to sewn-in labeling and other methods of decorative trimming. An assortment of heat-sealable applications is available including hot paper transfers, screen printed transfers, direct printing, application equipment and supplies, and digital printed transfers. When ordering machine parts, please include the model and serial numbers of your equipment. U.S.A.: Thermopatch Corporation P.O. Box 8007 Syracuse, New York 13217-8007 Australia: Thermopatch (Australia) Pty. Ltd. 477 Warrigal Road, Unit No. 9 Moorabbin, Victoria 3189 Telephone: 315-446-8110 Telephone: 011-61-3-9532-5722 Fax: 315-445-8046 Fax: 011-61-3-9532-5652 Toll Free: 800-252-6555 (in the USA only) Canada: Thermopatch (Canada) Incorporated 25 Groff Place, Unit No. 5 Kitchener, Ontario N2E 2L6 Netherlands: Thermopatch BV P.O. Box 50052 1305 AB Almere Netherlands Telephone: 519-748-5027 Telephone: 011-31-36-549-1111 Fax: 519-748-1543 Fax: 011-31-36-532-0398 Toll Free: 800-265-6416 (in Canada only)

B.P. 1011 Les Mureaux Cedex 78131 France Germany: Thermopatch Deutschland Grunteweg 33 26127 Oldenburg Deutschland Telephone: 011-33-1-3022-0808 Telephone: +49 441-380210 Fax: 011-33-1-3022-1866 Fax: +49 441-3802121 Internet Address: http://www.thermopatch.com E-mail Address: [email protected] If your country is not listed above, please contact Thermopatch Corporation or Thermopatch Netherlands.